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Journal of Mechanical
Engineering
and
Technology (IJMET), ISSN
0976 6340(Print),
INTERNATIONAL
JOURNAL
OF
MECHANICAL
ENGINEERING
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
IJMET
IAEME
Dr. S.B.Rane2
ABSTRACT
Purpose: The purpose of this paper is to re-design a lift truck frame (Chassis) with the optimum
mass while maintaining stress constraints. The paper also demonstrate how Optimization techniques
can be applied mainly when product is already launched in market and optimized design is to be
implemented without altering any existing assembly fitment parameters/functional requirement.
Methodology: This paper describes the use of topology and size optimization technique using CAE
software OptiStruct of Altair Engineering to redesign Frame of a lift Truck and comparison of result
using alternate solver Radioss.
Findings: Up to 15% weight reduction in frame is achieved without altering any existing assembly
fitment parameters or compromising any functional requirements. Also considerable cost saving of
Rs.10000 per vehicle is achieved through this process.
Practical Implications: It is completely feasible to implement the optimized design in actual
practice/production & other organization can also benefit by implementation of similar process.
Limitation: This paper has limitation in terms of further optimization using all the features since the
design is already ready and the frame production is continued. Therefore the optimization cannot be
achieved through major change in the shape which may affect the existing production activities.
Originality/Value: This paper can help derive common methodology for optimization techniques
specific to Industrial Equipment and other Off-highway equipment like Earthmoving and
Construction equipments.
Type of Paper: Applied Research.
Keywords: Hyper Works, Lift Truck, Structural Optimization, Size, Topology.
45
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
I. INTRODUCTION
Optimization [3] is a mathematical technique that deals with computing minima or maxima
of functions subjected to design variables or constrains. There are essentially two stages of the
design process in which structural optimization [2] can be applied. In the early stage of concept
generation, topology optimization [1] should be used to develop an efficient structure from the
beginning. At this level, an automatize variation of optimization parameters is proven useful to find
the best feasible design possible. In the later stage, shape and size optimization [6] should be used to
fine-tune the structure realized from the topology optimization. Using optimization in this manner
gives great possibilities to save time; mass as well as it may produce innovative designs. As first
design step topology optimization is used for finding out proper material distribution followed by
size optimization for computing optimal thickness of structural members of Frame.
The whole challenging task, starting with pre -processing, solving and post processing is
completed using Altairs HyperMesh, OptiStruct [4] and Hyper View FE package. Results are
compared using alternate solver of Altair Radioss [4] which are discussed in the concluding part.
II. PROCESS METHODOLOGY
Here is a simplified overview of the traditional design process and where the different types
of structural optimizations can be applied. There are basically two different areas where structural
optimization should be performed; in the early design phase where topology optimization is used to
generate a good concept and in the detailed design phase where size- and shape-optimization [7] is
used to further improve the structure.
1. Concept Generation
A flow chart for the concept generation is presented followed by a description of each step.
Choice of parameters and other details are discussed in the respective sections. The process of
concept generation should be seen as an iterative process where the problem formulation and design
domain is incrementally improved until the best possible solution is found. Refer Fig 1.
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
3. Material Details
Hot Rolled Structural Steel Specification as per IS 2062:2011 [10].
Grade: E250 A (Old Designation: Fe 410 WA)
Tensile Strength:
410 Mpa
Yield Strength:
240 Mpa
Youngs Modulus:
210 Gpa
Poissons Ratio:
0.3
Factor of Safety:
48
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
Table 1
Component
Weight in Kgs
Rated Load
5000
Lifting Mechanism
1500
300
Transmission
300
Engine
550
Rear Axle
145
Counter Weight
2150
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
7. Size Optimization
OptiStruct has the capability of performing size optimization. Size optimization can be
performed simultaneously with the other types of optimization. In size optimization, the properties of
structural elements such as shell thickness, beam cross-sectional properties, spring stiffness, and
mass are modified to solve the optimization problem.
The output design by topology optimization with introducing cutouts is set for size
optimization to get the optimized thickness of all structural members. The following criteria are
defined for size optimization.
The output thickness result are seen in Fig.7
Design Variable : Thickness of the components
Design Objective: Minimize mass
Design Constraint: Stress with specified limit
Design by size optimization is considered for remaining load cases followed by adjustment of
cut outs for maintaining C. G. location of Frame
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
DESIGN
VARIABLE
I.D
06
07
08
09
10
UPPER
BOUND
2.000E+01
2.000E+01
1.200E+01
1.600E+01
2.400E+01
52
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
Existing design
Optimized design
Stress (Mpa)
70.8
79.7
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
Solver
OptiStruct
Radioss
Stress (Mpa)
80
86
54
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
Future scope would be towards implementation of Shape Optimization along with Topology
optimization to limit the design domain and shape in early phase of development.
Also Dynamic load conditions would be simulated so as to have optimum design which would
ensure excessive safety factor is not considered.
12. Acknowledgement
We would like to express our gratitude to Mr.Pinaki Ghosh, GM - Engineering R&D for
giving us an opportunity to work on this project in Voltas Material Handling Pvt Ltd, Pune and
providing the necessary approval for publishing this paper. Special thanks to Mr.Khusal Kesrod,
Design tech for his support and encouragement throughout this project. And last but not the least
senior Professors and colleagues from Sardar Patel College of Engineering, Mumbai for their
valuable guidance and constant encouragement towards completion of this research.
VI. REFERENCES
Thesis:
1.
Martin Fagerstrom and Magnus Jansson, 2002, Topology optimization in the design
process, Master's thesis, Chalmers University of Technology.
Books:
2.
3.
4.
Martin Philip Bendsoe, 1995, Optimization of Structural Topology, Shape and Material,
Springer-Verlag Berlin Heidelberg.
Singiresu S. Rao, 1996, Engineering Optimization | Theory and Practice, John Wiley &
Sons, third edition.
Altair Engineering Inc, 2009, OptiStruct 10.0 help files.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 10, October (2014), pp. 45-56 IAEME
Proceedings Papers:
5.
6.
7.
Dr S.B.Rane, Harshal Shirodkar, P.Sridhar Reddy, 2013, Finite Element Analysis and
Optimization of Forklift Chassis, India Altair Technology Conference.
Gerald Kress and David Keller, 2007, Structural Optimization, Swiss Federal Institute of
Technology Zurich.
Marco Cavazzuti and Luca Splendi, Structural optimization of automotive Chassis: Theory,
set up, design, Mille Chili Lab, Dipartimento di Ingegneria Meccanica Civile, Modena, Italy.
Journal Papers:
8.
Hirak Patel, Khushbu C. Panchal, Chetan S. Jadav, April 2013, Structural Analysis of Truck
Chassis Frame and Design Optimization for Weight Reduction, International Journal of
Engineering and Advanced Technology (IJEAT), ISSN: 2249 8958, Volume-2, Issue-4.
Standards:
9.
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